Multi-stage hydroprocessing

ABSTRACT

A process for hydroprocessing liquid petroleum and chemical streams in two or more hydroprocessing stages wherein the liquid and vapor products from the first stage are sent to a separation zone wherein a liquid phase fraction is separated from a vapor phse fraction which contains vaporized heary hydrocarbon components. The vapor phase fraction is passed to a sorption zone wherein at least a portion of the heavy hydrocarbon components is removed. Both the liquid phase fraction and the sorbed heavy hydrocarbon components are sent to at least one additional hydroprocessing stage.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This is a continuation-in-part of U.S. Ser. No. 09/457,437 filedDec. 7, 1999, which was based on Provisional Application 60/111,176filed on Dec. 7, 1998.

BACKGROUND OF THE DISCLOSURE

[0002] 1. Field of the Invention

[0003] The present invention relates to a process for hydroprocessingliquid petroleum and chemical streams in two or more hydroprocessingstages wherein the liquid and vapor products from the first stage aresent to a separation zone wherein a liquid phase fraction is separatedfrom a vapor phse fraction which contains vaporized heary hydrocarboncomponents. The vapor phase fraction is passed to a sorption zonewherein at least a portion of the heavy hydrocarbon components isremoved. Both the liquid phase fraction and the sorbed heavy hydrocarboncomponents are sent to at least one additional hydroprocessing stage.

[0004] 2. Background of the Invention

[0005] As supplies of lighter and cleaner feedstocks dwindle, thepetroleum industry will need to rely more heavily on relatively highboiling feedstocks derived from such materials as coal, tar sands,oil-shale, and heavy crudes. Such feedstocks generally containsignificantly more undesirable components, especially from anenvironmental point of view. Such undesirable components includehalides, metals and heteroatoms such as sulfur, nitrogen, and oxygen.Furthermore, specifications for fuels, lubricants, and chemicalproducts, with respect to such undesirable components, are continuallybecoming tighter. Consequently, such feedstocks and product streamsrequire more severe upgrading in order to reduce the content of suchundesirable components. More severe upgrading, of course, addsconsiderably to the expense of processing these petroleum streams.

[0006] Hydroprocessing, which includes hydroconversion, hydrocracking,hydrotreating, and hydroisomerization, plays an important role inupgrading petroleum streams to meet the more stringent qualityrequirements. For example, there is an increasing demand for improvedheteroatom removal, aromatic saturation, and boiling point reduction.Much work is presently being done in hydrotreating because of greaterdemands for the removal of heteroatoms, most notably sulfur, fromtransportation and heating fuel streams. Hydrotreating, or in the caseof sulfur removal, hydrodesulfurization, is well known in the art andusually requires treating the petroleum streams with hydrogen in thepresence of a supported catalyst at hydrotreating conditions. Thecatalyst is typically comprised of a Group VI metal with one or moreGroup VIII metals as promoters on a refractory support. Hydrotreatingcatalysts that are particularly suitable for hydrodesulfurization andhydrodenitrogenation generally contain molybdenum or tungsten on aluminapromoted with a metal such as cobalt, nickel, iron or a combinationthereof. Cobalt promoted molybdenum on alumina catalysts are most widelyused for hydrodesulfurization, while nickel promoted molybdenum onalumina catalysts are the most widely used for hydrodenitrogenation andaromatic saturation.

[0007] Much work is being done to develop more active catalysts andimproved reaction vessel designs in order to meet the demand for moreeffective hydroprocessing processes. Various improved hardwareconfigurations have been suggested. One such configuration is acountercurrent design wherein the feedstock flows downward throughsuccessive catalyst beds counter to upflowing treat gas, which istypically a hydrogen containing treat-gas. The downstream catalyst beds,relative to the flow of feed can contain high performance, but otherwisemore sulfur sensitive catalysts because the upflowing treat gas carriesaway heteroatom components such as H₂S and NH₃ that are deleterious tothe sulfur and nitrogen sensitive catalysts. While such countercurrentreactors have commercial potential, they never the less are susceptibleto flooding. That is, where upflowing treat gas and gaseous productsimpede the downward flow of feed.

[0008] Other process configurations include the use of multiple reactionstages, either in a single reaction vessel, or in separate reactionvessels. More sulfur sensitive catalysts can be used in downstreamstages, as the level of heteroatom components becomes successivelylower. European Patent Application 93200165.4 teaches a two-stagehydrotreating process performed in a single reaction vessel, but thereis no suggestion of a unique stripping arrangement for the liquidreaction stream from each reaction stage.

[0009] As discussed above, it is at times advantageous to conducthydroprocessing in a two-stage operation where the combined liquid/vaporproduct from the first reactor is separated and the liquid combined withclean treat gas is passed to a second reaction stage. There is however aproblem associated with the separated vapor phase product streamproduced from the liquid/vapor separation step. This vapor phase, whichwill typically contain significant amounts of vaporized hydrocarbonincluding a high boiling tail. The entire hydrocarbon portion, butparticularly the hig boiling, or heavy tail, may require additionalhydroprocessing to meet product quality specifications; this additionalhydroprocessing may be very difficult and expensive to accomplish. Anexample of particular commercial interest at this time is the two-stagehydrotreating of diesel fuel to meet legislated reductions in sulfurlevels from the current specification of 500 wppm down to 50 wppm.

[0010] While there is a substantial amount of art relating tohydroprocessing catalysts, as well as process designs, there stillremains a need in the art for process designs that offer furtherimprovement.

SUMMARY OF THE INVENTION

[0011] In accordance with the present invention there is provided a twostage process for hydroprocessing a hydrocarbonaceous feedstock whichprocess comprises:

[0012] (a) reacting said feedstock in a first reaction stage in thepresence of a hydrogen-containing treat gas, said reaction stagecontaining one or more reaction zones operated at hydroprocessingconditions wherein each reaction zone contains a bed of hydroprocessingcatalyst;

[0013] (b) passing the resulting product stream to a separation zonewherein a vapor phase fraction and a liquid phase fraction are produced,which vapor phase fraction contains vaporized high boiling hydrcarboncomponents;

[0014] (c) conducting at least a portion of said vapor phase fraction toa sorption zone wherein it is contacted with a sorption agent that is ata temperature less than that of said vapor phase fraction, therebysorbing at least a portion of the vaporized high boiling hydrocarboncomponents from the vapor phase fraction;

[0015] (d) conducting said liquid phase fraction to a second reactionstage in the presence of a hydrogen-containing treat gas, said reactionstage containing one or more reaction zones operated at hydroprocessingconditions wherein each reaction zone contains a bed of hydroprocessingcatalyst; and

[0016] e) collecting the hydroprocessed product stream for said secondreaction stage.

[0017] In preferred embodiments of the present invention the vapor phasefraction can be treated by: (i) partial condensation of the vapor phasestream, (ii) usage of a contacting device with partial condensation andreflux to achieve multiple vapor liquid equilibrium stages, (iii)contacting the vapor phase stream with a heavy liquid stream, and (iv) adephlegmator.

[0018] In another preferred embodiment of the present invention thecontacting with vapor phase fraction is contacted with the sorptionagent in a trayed or packed device to result in multiple vapor liquidequilibrium stages.

[0019] In yet another preferred embodiment of the present invention thesorption agent is a cooled heavy liquid liquid product from step (d).

BRIEF DESCRIPTION OF THE FIGURE

[0020] The FIGURE hereof shows multiple reaction vessels of the presentinvention showing separation of the liquid phase product from the vaporphase product and further processing of the liquid phase product stream.

DETAILED DESCRIPTION OF THE INVENTION

[0021] Feedstocks suitable for use in such systems include those rangingfrom the naphtha boiling range to heavy feedstocks, such as gas oils andresids. Typically, the boiling range will be from about 40° C. to about1000° C. Non-limiting examples of such feeds which can be used in thepractice of the present invention include vacuum resid, atmosphericresid, vacuum gas oil (VGO), atmospheric gas oil (AGO), heavyatmospheric gas oil (HAGO), steam cracked gas oil (SCGO), deasphaltedoil (DAO), and light cat cycle oil (LCCO).

[0022] Non-limiting examples of hydroprocessing processes which can bepracticed by the present invention include the hydroconversion of heavypetroleum feedstocks to lower boiling products; the hydrocracking ofdistillate, and higher boiling range feedstocks; the hydrotreating ofvarious petroleum feedstocks to remove heteroatoms, such as sulfur,nitrogen, and oxygen; the hydrogenation of aromatics; thehydroisomerization and/or catalytic dewaxing of waxes, particularlyFischer-Tropsch waxes; and the demetallation of heavy streams.Ring-opening, particularly of naphthenic rings, can also be considered ahydroprocessing process.

[0023] The practice of the present invention is applicable to allliquid-vapor countercurrent refinery and chemical processes. Feedstockssuitable for use in the practice of the present invention include thoseranging from the naphtha boiling range to heavy feedstocks, such as gasoils and resids. Typically, the boiling range will be from about 40° C.to about 1000° C. Non-limiting examples of such heavy feedstocks includevacuum resid, atmospheric resid, vacuum gas oil (VGO), atmospheric gasoil (AGO), heavy atmospheric gas oil (HAGO), steam cracked gas oil(SCGO), deasphalted oil (DAO), and light cat cycle oil (LCCO). Thefeedstock can also be a Fischer-Tropsch reactor product stream.

[0024] The process of the present invention can be better understood bya description of a preferred embodiment illustrated by the FIGUREhereof. The current invention offers an improvement over the prior artby use of a step to remove the heavy tail from the vapor stream androute it to second stage hydroprocessing (or another disposition) whereit can more efficiently be processed. The term “heavy tail' as usedherein means that portion of the vapor phase fraction that is composedof heavy hydrocarbon components that typically boil in excess of about315° C., preferably in excess of about 345° C. The vapor phase fraction,because of the presence of this heavy tail, typically contains too higha level of sulfur to be blended into the final product. The majority ofthe sulfur present in the vapor phase fraction can be found in the heavytail. Not only does the high sulfur content of this heavy tail preventthe vapor phase fraction from being blended into the final product, butthey would normally require the presence of a third hydroprocessingstage to remove them because of their high boiling points. Removal ofthis heavy tail will thus allow the vapor product to be furtherprocessed much more easily or may even allow it to be blended into thefinal product without further processing. For purposes of discussion,the reaction stages will be assumed to be hydrotreating stages, althoughthey can just as well be any of the other aforementioned types ofhydroprocessing stages. Miscellaneous reaction vessel internals, valves,pumps, thermocouples, and heat transfer devices etc. are not shown ineither figures for simplicity. The FIGURE hereof shows reaction vesselR1 a that contains reaction zones10 a and 10 b, each of which iscomprised of a bed of hydroprocessing catalyst. It is preferred that thecatalyst be in the reactor as a fixed bed, although other types ofcatalyst arrangements can be used, such as slurry or ebullating beds.Upstream of each reaction zone is a non-reaction zone 12 a and 12 b. Thenon-reaction zone is typically void of catalyst, that is, it will be anempty section in the vessel with respect to catalyst. There may also beprovided a liquid distribution means LD upstream of each reaction stage.The type of liquid distribution means is believed not to limit thepractice of the present invention, but a tray arrangement is preferred,such as sieve trays, bubble cap trays, or trays with spray nozzles,chimneys, tubes, etc.

[0025] The feedstream is fed to reaction vessel R1 via line 14 alongwith a hydrogen-containing treat gas via line 16. The feedstream andhydrogen-containing treat gas pass, cocurrently, through the one or morereaction zones of reaction vessel R1, which represents the firsthydroprocessing stage. A combined liquid phase product stream and vaporphase product stream exit reaction vessel R1 via line 18 and intoseparation zone S wherein a liquid separated from a vapor phasefraction. The liquid phase fraction will typically be one that hascomponents boiling in the range from about 150° C. to about 345° C. Thevapor phase fraction will contain lighter components, but it will alsocontain a significant amount of higher boiling hydrocarbon components.These higher boiling components will boiling in the range of 315° C. orgreater, even in the range of 345° C. or greater.

[0026] The vapor phase fraction is passed to sorption zone ST via line20 wherein it is contacted with a sorption agent STA that removes atleast a portion, preferably substantially all, of the high boilinghydrocarbon component. Non-limiting examples of sorption agents suitablefor use here include heavy boiling range streams, such as gas oils andresids. Such streams will typically boil in the range of about 530° C.to about 950° C. Non-limiting examples of such steams inlcude vaccumresid, atmospheric resid, vacuum gas oil (VGO), atmospheric gas oil(AGO), heavy atmospheric gas oil (HAGO), steam cracked gas oil (SCGO),deasphalted oil (DAO), and light cat cycle oil (LCCO). Preferred are thegas oils.

[0027] It will be understood that the sorption device can be replaced byany other suitable means for removing the heavy tail from the vaporfraction. For example, in a preferred embodiment of the presentinvention the removal of the heavy tail comprises: (i) partialcondensation of the vapor phase stream, (ii) usage of a contactingdevice with partial condensation and reflux to achieve multiple vaporliquid equilibrium stages, (iii) contacting the vapor phase stream witha heavy liquid stream, and (iv) a dephlegmator.

[0028] The sorbed vapor phase fraction is collected overhead via line22. The heavy hydrocarbon components from the stripper are passed vialine 24 to second stage hydroprocessing unit R2. The liquid phasefraction from separation zone S is passed to reaction vessel R2 via line26, along with fresh hydrogen-containing treat gas via line 28.Introducing clean treat gas (gas substantially free of H₂S and NH₃)allows the second reaction zone to operate more efficiently due to areduction in the activity suppression effects exerted by H₂S and NH₃ andan increase in H₂ partial pressure. This type of two-stage operation isparticularly attractive for very deep removal of sulfur and nitrogen orwhen a more sensitive catalyst (i.e., hydrocracking, aromaticsaturation, etc) is used in the second reactor. The liquid/vaporseparation step can be a simple flash or may involve the addition ofstripping steam or gas to improve the removal of H₂S and NH_(3.)

[0029] In reactor R2, the combined liquid stream and treat gas arepassed through one or more catalyst beds, or reaction zones, 26 a and 26b and a product stream exits reaction vessel R2 via line 30. Reactionvessel also contains non-reaction zones 28 a and 28 b upstream of eachreaction zone. LD is as defined for R1. The catalyst in this secondreaction stage can be a high performance catalyst which otherwise can bemore sensitive to heteroatom poisoning because of the lower level ofheteroatoms in the treated feedstream, as well as low levels ofheteroatom species H₂S and NH₃ in the treat gas.

[0030] As previously mentioned, the reaction stages can contain anycombination of catalysts depending on the feedstock and the intendedfinal product. For example, it may be desirable to remove as much of theheteroatoms from the feedstock as possible. In such a case, bothreaction stages will contain a hydrotreating catalyst. The catalyst inthe downstream reaction stage can be more heteroatom sensitive becausethe liquid stream entering that stage will contain lower amounts ofheteroatoms than the original feedstream and reaction inhibitors, suchas H₂S and NH₃, have been reduced. When the present invention is usedfor hydrotreating to remove substantially all of the heteroatoms fromthe feedstream, it is preferred that the first reaction stage contain aCo—Mo on a refractory support catalyst and a downstream reaction stagecontain a Ni—Mo on a refractory support catalyst.

[0031] The term “hydrotreating” as used herein refers to processeswherein a hydrogen-containing treat gas is used in the presence of asuitable catalyst that is primarily active for the removal ofheteroatoms, such as sulfur, and nitrogen, and for some hydrogenation ofaromatics. Suitable hydrotreating catalysts for use in the presentinvention are any conventional hydrotreating catalysts and includesthose which are comprised of at least one Group VIII metal, preferablyFe, Co and Ni, more preferably Co and/or Ni, and most preferably Co; andat least one Group VI metal, preferably Mo and W, more preferably Mo, ona high surface area support material, preferably alumina. Other suitablehydrotreating catalysts include zeolitic catalysts, as well as noblemetal catalysts where the noble metal is selected from Pd and Pt. It iswithin the scope of the present invention that more than one type ofhydrotreating catalyst be used in the same reaction vessel. The GroupVIII metal is typically present in an amount ranging from about 2 to 20wt. %, preferably from about 4 to 12%. The Group VI metal will typicallybe present in an amount ranging from about 5 to 50 wt. %, preferablyfrom about 10 to 40 wt. %, and more preferably from about 20 to 30 wt.%. All metals weight percents are on support. By “on support” we meanthat the percents are based on the weight of the support. For example,if the support were to weigh 100 g. then 20 wt. % Group VIII metal wouldmean that 20 g. of Group VIII metal was on the support. Typicalhydrotreating temperatures range from about 100° C. to about 400° C.with pressures from about 50 psig to about 3,000 psig, preferably fromabout 50 psig to about 2,500 psig. If the feedstock contains relativelylow levels of heteroatoms, then the hydrotreating step may be eliminatedand the feedstock passed directly to an aromatic saturation,hydrocracking, and/or ring-opening reaction stage.

[0032] In another embodiment of the present invention the vapor productstream from separation zone S is passed to a condensation zone and theresulting liquid condensate is combined with the liquid phase productstream exiting separation zone S and is passed to reaction vessel R2.The off-gas from the condensation zone is collected or passed forfurther processing.

[0033] The reaction stages used in the practice of the present inventionare operated at suitable temperatures and pressures for the desiredreaction. For example, typical hydroprocessing temperatures will rangefrom about 40° C. to about 450° C. at pressures from about 50 psig toabout 3,000 psig, preferably 50 to 2,500 psig.

[0034] For purposes of hydroprocessing, the term “hydrogen-containingtreat gas” means a treat gas stream containing at least an effectiveamount of hydrogen for the intended reaction. The treat gas streamintroduced to the reaction vessel will preferably contain at least about50 vol. %, more preferably at least about 75 vol. % hydrogen. It ispreferred that the hydrogen-containing treat gas be make-uphydrogen-rich gas, preferably substantially pure hydrogen.

[0035] Depending on the nature of the feedstock and the desired level ofupgrading, more than two reaction stages may be preferred. For example,when the desired product is a distillate fuel, it is preferred that itcontain reduced levels of sulfur and nitrogen. Further, distillatescontaining paraffins, especially linear paraffins are often preferredover naphthenes, which are often preferred over aromatics. To achievethis, at least one downstream catalyst will be selected from the groupconsisting of hydrotreating catalysts, hydrocracking catalysts, aromaticsaturation catalysts, and ring-opening catalysts. If it is economicallyfeasible to produce a product stream with high levels of paraffins, thenthe downstream reaction stages will preferably include an aromaticsaturation stage and a ring-opening stage.

[0036] If one of the downstream reaction stages is a hydrocrackingstage, the catalyst can be any suitable conventional hydrocrackingcatalyst run at typical hydrocracking conditions. Typical hydrocrackingcatalysts are described in U.S. Pat. No. 4,921,595 to UOP, which isincorporated herein by reference. Such catalysts are typically comprisedof a Group VIII metal hydrogenating component on a zeolite crackingbase. The zeolite cracking bases are sometimes referred to in the art asmolecular sieves, and are generally composed of silica, alumina, and oneor more exchangeable cations such as sodium, magnesium, calcium, rareearth metals, etc. Crystal pores of relatively uniform diameter betweenabout 4 and 12 Angstroms further characterize them. It is preferred touse zeolites having a relatively high silica/alumina mole ratio greaterthan about 3, preferably greater than about 6. Suitable zeolites foundin nature include mordenite, clinoptiliolite, ferrierite, dachiardite,chabazite, erionite, and faujasite. Suitable synthetic zeolites includethe Beta, X, Y, and L crystal types, e.g., synthetic faujasite,mordenite, ZSM-5, MCM-22 and the larger pore varieties of the ZSM andMCM series. A particularly preferred zeolite is any member of thefaujasite family, see Tracy et al., Proc. of the Royal Soc., 1996, Vol.452, p. 813. It is to be understood that these zeolites may includedemetallated zeolites that are understood to include significant porevolume in the mesopore range, i.e., 20 to 500 Angstroms. Non-limitingexamples of Group VIII metals that may be used on the hydrocrackingcatalysts include iron cobalt, nickel, ruthenium, rhodium, palladium,osmium, iridium, and platinum. Preferred are platinum and palladium,with platinum being more preferred. The amount of Group VIII metal willrange from about 0.05 wt. % to 30 wt. %, based on the total weight ofthe catalyst. If the metal is a Group VIII noble metal, it is preferredto use about 0.05 to about 2 wt. %. Hydrocracking conditions includetemperatures from about 200° to 425° C., preferably from about 220° to330° C., more preferably from about 245° to 315° C.; pressure of about200 psig to about 3,000 psig; and liquid hourly space velocity fromabout 0.5 to 10 V/V/Hr, preferably from about 1 to 5 V/V/Hr.

[0037] Non-limiting examples of aromatic hydrogenation catalysts includenickel, cobalt-molybdenum, nickel-molybdenum, and nickel-tungsten. Noblemetal containing catalysts can also be used. Non-limiting examples ofnoble metal catalysts include those based on platinum and/or palladium,which is preferably supported on a suitable support material, typicallya refractory oxide material such as alumina, silica, alumina-silica,kieselguhr, diatomaceous earth, magnesia, and zirconia. Zeoliticsupports can also be used. Such catalysts are typically susceptible tosulfur and nitrogen poisoning. The aromatic saturation stage ispreferably operated at a temperature from about 40° C. to about 400° C.,more preferably from about 260° C. to about 350° C., at a pressure fromabout 100 psig to about 3,000 psig, preferably from about 200 psig toabout 1,200 psig, and at a liquid hourly space velocity (LHSV) of fromabout 0.3 V/V/Hr. to about 2 V/V/Hr.

[0038] The liquid phase in the reaction vessels used in the presentinvention will typically be the higher boiling point components of thefeed. The vapor phase will typically be a mixture of hydrogen-containingtreat gas, heteroatom impurities like H₂S and NH₃, and vaporizedlower-boiling components in the fresh feed, as well as light products ofhydroprocessing reactions. If the vapor phase effluent still requiresfurther hydroprocessing, it can be passed to a vapor phase reactionstage containing additional hydroprocessing catalyst and subjected tosuitable hydroprocessing conditions for further reaction. It is alsowithin the scope of the present invention that a feedstock that alreadycontains adequately low levels of heteroatoms be fed directly into thereaction stage for aromatic saturation and/or cracking.

[0039] The present invention can be better understood by reference tothe following example that is present for illustrative purposes only andis not to be taken as limiting the invention in any way.

EXAMPLE

[0040] A diesel oil feed (previously hydrotreated) containing 180 wppmof sulfur was processed in a counter current reactor pilot unit.Operating conditions were 185 psig total pressure, 350° C., 2 lhsv(liquid hourly space velocity), and treat gas rate of 1114 scf/b(standard cubic feet per barrel) H₂. The catalyst used was acommercially available CoMo on alumina containing about 3.8 wt. % Co andabout 13.2 wt. % Mo. The liquid product leaving the bottom of thereactor was approximately 70 wt. % of the feed and had a sulfur contentof 44 wppm. The vapor leaving the top of the reactor with the treat gas,approximately 30 wt. % of the feed, was condensed and found to contain93 wppm sulfur. Blending the two products would result in a totalproduct having a sulfur content of 59 wppm, which exceeds theanticipated environmental specifications.

[0041] The condensed vapor was then fractionated by distillation and thevarious cuts were analyzed for sulfur content: Boiling Range ° F. Yield(wt. %) Sulfur (wppm)  0-400 10.4 <10  400-450 12.5 11 450-500 14.8 11500-550 26.0 16 550-600 19.8 24 600-650 11.9 221  650+  4.7 946 

[0042] Through this analysis it was discovered that almost half of thesulfur was contained in less than 5% of the heaviest material (650°F.+(344° C.+) boiling range material) and that the vast majority was inthe 600° F.+(315° C.+) material. If the heavy tail is removed from thecondensed vapor stream then the resultant stream can be blended with thebottoms liquid to give an overall product that is of high quality. Thisalso shows that the sulfur species can be concentrated for furthertreatment.

What is claimed is:
 1. A two stage process for hydroprocessing ahydrocarbonaceous feedstock which process comprises: (a) reacting saidfeedstock in a first reaction stage in the presence of ahydrogen-containing treat gas, said reaction stage containing one ormore reaction zones operated at hydroprocessing conditions wherein eachreaction zone contains a bed of hydroprocessing catalyst; (b) passingthe resulting product stream to a separation zone wherein a vapor phasefraction and a liquid phase fraction are produced, which vapor phasefraction containing vaporized high boiling hydrcarbon components; (c)conducting at least a portion of said vapor phase fraction to a sorptionzone wherein it is contacted with a sorption agent that is at atemperature less than that of said vapor phase fraction, thereby sorbingat least a portion of the vaporized high boiling hydrocarbon componentsfrom the vapor phase fraction; (d) conducting said liquid phase fractionto a second reaction stage in the presence of a hydrogen-containingtreat gas, said reaction stage containing one or more reaction zonesoperated at hydroprocessing conditions wherein each reaction zonecontains a bed of hydroprocessing catalyst; and e) collecting thehydroprocessed product stream for said second reaction stage.
 2. Theprocess of claim 1 wherein step (c) above comprises one or more of: (i)partial condensation of the vapor phase fraction, (ii) usage of acontacting device with partial condensation and reflux to achievemultiple vapor liquid equilibrium stages, (iii) contacting the vaporphase stream with a heavy liquid stream, and (iv) use of a dephlegmator.3. The process of claim 1 wherein the contacting with the vapor phasefraction is performed in a trayed or packed device to result in multiplevapor liquid equilibrium stages.
 4. The process of claim 3 wherein thesorption agent is selected from the group consisting of vaccum resid,atmospheric resid, vacuum gas oil, atmospheric gas oil, heavyatmospheric gas oil, steam cracked gas oil, deasphalted oil, light catcycle oil, and the hydroprocessed product from first stagehydroprocessing.
 5. The process of claim 4 wherein the sorption agent isthe hydroprocessed product from first stage hydroprocessing.
 6. Theprocess of claim 3 wherein heavy hydrocarbon components sorbed from thevapor phase fraction are passed to the second reaction stage.
 7. Theprocess of claim 1 wherein the hydrocarbonaceous feedstream is a heavyfeedstock selected from the group consisting of vacuum resid,atmospheric resid, vacuum gas oil, atmospheric gas oil, heavyatmospheric gas oil, steam cracked gas oil, desaphalted oil, and lightcat cycle oil.
 8. The process of claim 1 wherein the feedstock is aFischer-Tropsch reactor product stream.